Method of forming load bearing insert and insert for ceramic matrix composite turbine components

Abstract

A method of forming a gas turbine engine component includes the steps of forming a component shape from a plurality of fabric layers of ceramic matrix composite. The component has an outer surface. An insert is formed from a plurality of fabric layers of ceramic matrix composites into a cup-shaped intermediate insert. The intermediate insert member is densified. Then a final insert is inserted between radially outer layers and radially inner layers on the outer surface. The method then densifies the component. A gas turbine engine component and a gas turbine engine are also disclosed.

What is claimed is: 
     
         1 . A method of forming a gas turbine engine component comprising the steps of:
 forming a component shape from a plurality of fabric layers of ceramic matrix composite, the component having an outer surface;   forming an insert from a plurality of fabric layers of ceramic matrix composites into a cup-shaped intermediate insert;   densifying the intermediate insert member;   then, inserting a final insert between radially outer layers and radially inner layers on the outer surface; and   densifying the component.   
     
     
         2 . The method as set forth in  claim 1 , further including the step of cutting ends of the intermediate insert away to form at least two of the final inserts. 
     
     
         3 . The method as set forth in  claim 2 , wherein the intermediate insert is formed from a plurality of cup-shaped stacks and then assembling the plurality of stacks to form the intermediate insert. 
     
     
         4 . The method as set forth in  claim 3 , wherein the plurality of cup-shaped stacks are each formed of a plurality of layers compressed together. 
     
     
         5 . The method as set forth in  claim 4 , wherein all of the plurality of cup-shaped stacks are compressed together at one time. 
     
     
         6 . The method as set forth in  claim 4 , wherein at least two sub-assemblies of the cup-shaped stacks are compressed together, and then the at least two sub-assemblies of the cup-shaped stacks are then brought together to be compressed together in another compression step. 
     
     
         7 . The method as set forth in  claim 6 , wherein the cup-shaped stacks are each formed of a plurality of layers. 
     
     
         8 . The method as set forth in  claim 4 , wherein the radially outer layers capture the insert. 
     
     
         9 . The method as set forth in  claim 1 , wherein the radially outer layers capture the insert. 
     
     
         10 . The method as set forth in  claim 1 , wherein the gas turbine engine component is a vane. 
     
     
         11 . The method as set forth in  claim 1 , wherein the plurality of ceramic matrix composite layers forming the intermediate insert are cut at the same time. 
     
     
         12 . The method as set forth in  claim 11 , wherein the final insert has an endface to provide a reaction surface against a mount member. 
     
     
         13 . The method as set forth in  claim 1 , wherein the plurality of layers of ceramic matrix composite are initially planar, but when formed into the cup-shaped intermediate insert, the originally planar layers have ends which are bent relative to a central portion to form an arch-shape. 
     
     
         14 . The method as set forth in  claim 13 , wherein the final insert is mounted onto a planar inner surface in the component. 
     
     
         15 . The method as set forth in  claim 14 , wherein the ends of the final insert have fibers extending in a direction which has at least a component normal to a planar surface of the inner surface. 
     
     
         16 . A gas turbine engine component comprising:
 an inner surface and an outer surface, with the outer surface and the inner surface being formed of ceramic matrix composite fabric layers, and said outer surface having a mount location and a mount member, the mount member being in contact with an insert that is inserted within outer layers of the outer surface to form a thickened portion having an end surface that will react against forces from the mount member, and the insert also being formed of a plurality of ceramic matrix composite fabric layers; and   the ceramic matrix composite fiber layers having an arch-shape such that the fabric layers have ends which are bent relative to a central portion, and such that ends have at least a component in a direction normal to a planar surface of inner layers of the outer surface.   
     
     
         17 . The gas turbine engine component as set forth in  claim 16 , wherein the component is a vane having an airfoil and inner and outer platforms, and the insert being on one of the inner and outer platforms. 
     
     
         18 . The gas turbine engine component as set forth in  claim 17 , wherein the insert being on the outer platform. 
     
     
         19 . A gas turbine engine comprising:
 a compressor section, a combustor and a turbine section, the turbine section including rotating turbine blades and at least one stationary component mounted adjacent a rotating turbine blade;   the stationary component having an inner surface and an outer surface, the outer surface and the inner surface being formed of ceramic matrix composite layers, and said outer surface having a mount location and a mount member, the mount member being in contact with an insert that is inserted within outer layers of the outer surface to form a thickened portion having an end surface that will react against forces from the mount member, and the insert also being formed of a plurality of ceramic matrix composite fabric layers; and   the insert ceramic matrix composite fiber layers having an arch-shape such that the fabric layers have ends which are bent relative to a central portion, and such that ends have at least a component in a direction normal to a planar surface of inner layers of the outer surface.   
     
     
         20 . The gas turbine engine as set forth in  claim 19 , wherein the component is a vane having an airfoil and inner and outer platforms, and the insert being on one of the inner and outer platforms.